OM-253 392J 2015−08

Processes
Multiprocess Welding

Description

Arc Welding Power Source

Wire Feeder

Multimatic 200

Visit our website at

File: Multiprocess
www.MillerWelds.com
 From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard. particular model are also provided.

Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2009−09
 TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-2. Unit Specifications For MIG (GMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-3. Unit Specifications For TIG (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-4. Unit Specifications For Stick (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-5. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-6. Duty Cycle And Overheating For MIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-7. Duty Cycle And Overheating For TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-8. Duty Cycle And Overheating For Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-2. Stick Welding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-3. TIG Welding Connections DCEN (Direct Current Electrode Negative) . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-4. Process/Polarity Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-5. Wire Welding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-6. Wire Gun Connection Inside Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-7. Connecting Shielding Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-8. Multi−Voltage Plug (MVP) Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-10. Extension Cord Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-11. Connecting 115 Volt Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-12. Connecting 1-Phase Input Power For 230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-13. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-14. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-2. Weld Parameter Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-3. Entering Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-4. Adjusting Display Contrast (Menu 1 Of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-5. Calibrating Drive Motor (Menu 2 Of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-6. Calibrating Spoolmate 100 Or Spoolmate 150 (Menu 3 Of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-7. Enable/Disable Auto−Cratert (Menu 4 Of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
 TABLE OF CONTENTS

6-8. Viewing Burn-In Information (Menu 5 Of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6-9. Viewing Software Information (Menu 6 Of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6-10. Viewing Primary Power Information (Menu 7 Of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6-11. Viewing Process Logs (Menu 8 Of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6-12. Viewing Error Logs (Menu 9 Of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6-13. Performing A Factory Reset (Menu 10 Of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SECTION 7 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-3. Changing Drive Roll Or Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-4. Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 9 − GMAW WELDING (MIG) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SECTION 10 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SECTION 11 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . . 61
11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or
AC Welding With Inverter Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY
 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2013−09
7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

1-2. Arc Welding Hazards

disconnect box or that cord plug is connected to a properly
The symbols shown below are used throughout this manual grounded receptacle outlet.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D When making input connections, attach proper grounding conduc-
to avoid the hazard. The safety information given below is tor first − double-check connections.
only a summary of the more complete safety information D Keep cords dry, free of oil and grease, and protected from hot metal
found in the Safety Standards listed in Section 1-5. Read and and sparks.
follow all Safety Standards. D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
Only qualified persons should install, operate, maintain, and wiring can kill.
repair this unit.
D Turn off all equipment when not in use.
During operation, keep everybody, especially children, away. D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
ELECTRIC SHOCK can kill. with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is or another electrode from a different machine.
electrically live whenever the output is on. The input D Do not touch electrode holders connected to two welding ma-
power circuit and machine internal circuits are also chines at the same time since double open-circuit voltage will be
live when power is on. In semiautomatic or automatic present.
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are D Use only well-maintained equipment. Repair or replace damaged
electrically live. Incorrectly installed or improperly parts at once. Maintain unit according to manual.
grounded equipment is a hazard. D Wear a safety harness if working above floor level.
D Do not touch live electrical parts. D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
D Wear dry, hole-free insulating gloves and body protection.
or worktable as near the weld as practical.
D Insulate yourself from work and ground using dry insulating mats
D Insulate work clamp when not connected to workpiece to prevent
or covers big enough to prevent any physical contact with the work
contact with any metal object.
or ground.
D Do not use AC output in damp areas, if movement is confined, or if D Do not connect more than one electrode or work cable to any
there is a danger of falling. single weld output terminal. Disconnect cable for process not in
use.
D Use AC output ONLY if required for the welding process.
D Use GFCI protection when operating auxiliary equipment in damp
D If AC output is required, use remote output control if present on
or wet locations.
unit.
D Additional safety precautions are required when any of the follow- SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
ing power sources AFTER removal of input power.
as floors, gratings, or scaffolds; when in cramped positions such D Turn Off inverter, disconnect input power, and discharge input
as sitting, kneeling, or lying; or when there is a high risk of unavoid- capacitors according to instructions in Maintenance Section
able or accidental contact with the workpiece or ground. For these before touching any parts.
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual HOT PARTS can burn.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder D Do not touch hot parts bare handed.
is recommended. And, do not work alone!
D Allow cooling period before working on equip-
D Disconnect input power or stop engine before installing or ment.
servicing this equipment. Lockout/tagout input power according to D To handle hot parts, use proper tools and/or
OSHA 29 CFR 1910.147 (see Safety Standards).
wear heavy, insulated welding gloves and
D Properly install, ground, and operate this equipment according to clothing to prevent burns.
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
OM- 253 392 Page 1
 D Remove stick electrode from holder or cut off welding wire at
FUMES AND GASES can be hazardous. contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free
these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high
health.
shoes, and a cap.
D Keep your head out of the fumes. Do not breathe the fumes. D Remove any combustibles, such as a butane lighter or matches,
D If inside, ventilate the area and/or use local forced ventilation at the from your person before doing any welding.
arc to remove welding fumes and gases. The recommended way D After completion of work, inspect area to ensure it is free of sparks,
to determine adequate ventilation is to sample for the composition glowing embers, and flames.
and quantity of fumes and gases to which personnel are exposed. D Use only correct fuses or circuit breakers. Do not oversize or by-
D If ventilation is poor, wear an approved air-supplied respirator. pass them.
D Read and understand the Safety Data Sheets (SDSs) and the D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
manufacturer’s instructions for adhesives, coatings, cleaners, for hot work and have a fire watcher and extinguisher nearby.
consumables, coolants, degreasers, fluxes, and metals. D Read and understand the Safety Data Sheets (SDSs) and the
D Work in a confined space only if it is well ventilated, or while manufacturer s instructions for adhesives, coatings, cleaners,
wearing an air-supplied respirator. Always have a trained watch- consumables, coolants, degreasers, fluxes, and metals.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- FLYING METAL or DIRT can injure eyes.
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op- D Welding, chipping, wire brushing, and grinding
erations. The heat and rays of the arc can react with vapors to form cause sparks and flying metal. As welds cool,
highly toxic and irritating gases. they can throw off slag.
D Do not weld on coated metals, such as galvanized, lead, or D Wear approved safety glasses with side
cadmium plated steel, unless the coating is removed from the weld shields even under your welding helmet.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements BUILDUP OF GAS can injure or kill.
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin. D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
Arc rays from the welding process produce intense approved air-supplied respirator.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the ELECTRIC AND MAGNETIC FIELDS (EMF)
weld. can affect Implanted Medical Devices.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and D Wearers of Pacemakers and other Implanted
sparks when welding or watching (see ANSI Z49.1 and Z87.1 Medical Devices should keep away.
listed in Safety Standards). D Implanted Medical Device wearers should consult their doctor
D Wear approved safety glasses with side shields under your and the device manufacturer before going near arc welding, spot
helmet. welding, gouging, plasma arc cutting, or induction heating
D Use protective screens or barriers to protect others from flash, operations.
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant mate- NOISE can damage hearing.
rial (leather, heavy cotton, wool). Body protection includes Noise from some processes or equipment can
oil-free clothing such as leather gloves, heavy shirt, cuffless damage hearing.
trousers, high shoes, and a cap.
D Wear approved ear protection if noise lev-
WELDING can cause fire or explosion. el is high.

Welding on closed containers, such as tanks, CYLINDERS can explode if damaged.

drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot Compressed gas cylinders contain gas under high
workpiece, and hot equipment can cause fires and pressure. If damaged, a cylinder can explode. Since
burns. Accidental contact of electrode to metal objects can cause gas cylinders are normally part of the welding
sparks, explosion, overheating, or fire. Check and be sure the area is process, be sure to treat them carefully.
safe before doing any welding.
D Protect compressed gas cylinders from excessive heat, mechani-
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If cal shocks, physical damage, slag, open flames, sparks, and arcs.
this is not possible, tightly cover them with approved covers. D Install cylinders in an upright position by securing to a stationary
D Do not weld where flying sparks can strike flammable material. support or cylinder rack to prevent falling or tipping.
D Protect yourself and others from flying sparks and hot metal. D Keep cylinders away from any welding or other electrical circuits.
D Be alert that welding sparks and hot materials from welding can D Never drape a welding torch over a gas cylinder.
easily go through small cracks and openings to adjacent areas.
D Never allow a welding electrode to touch any cylinder.
D Watch for fire, and keep a fire extinguisher nearby.
D Never weld on a pressurized cylinder − explosion will result.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side. D Use only correct compressed gas cylinders, regulators, hoses,
D Do not weld on containers that have held combustibles, or on and fittings designed for the specific application; maintain them
closed containers such as tanks, drums, or pipes unless they are and associated parts in good condition.
properly prepared according to AWS F4.1 and AWS A6.0 (see D Turn face away from valve outlet when opening cylinder valve. Do
Safety Standards). not stand in front of or behind the regulator when opening the valve.
D Do not weld where the atmosphere may contain flammable dust, D Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline). use or connected for use.
D Connect work cable to the work as close to the welding area as D Use the right equipment, correct procedures, and sufficient num-
practical to prevent welding current from traveling long, possibly ber of persons to lift and move cylinders.
unknown paths and causing electric shock, sparks, and fire D Read and follow instructions on compressed gas cylinders,
hazards. associated equipment, and Compressed Gas Association (CGA)
D Do not use welder to thaw frozen pipes. publication P-1 listed in Safety Standards.
OM- 253 392 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. MOVING PARTS can injure.

D Do not install or place unit on, over, or near D Keep away from moving parts such as fans.
combustible surfaces. D Keep all doors, panels, covers, and guards
D Do not install unit near flammables. closed and securely in place.
D Do not overload building wiring − be sure power supply system is D Have only qualified persons remove doors, panels, covers, or
properly sized, rated, and protected to handle this unit. guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
READ INSTRUCTIONS.
extend beyond opposite side of unit.
D Read and follow all labels and the Owner’s
D Keep equipment (cables and cords) away from moving vehicles Manual carefully before installing, operating, or
when working from an aerial location. servicing unit. Read the safety information at
D Follow the guidelines in the Applications Manual for the Revised the beginning of the manual and in each
NIOSH Lifting Equation (Publication No. 94−110) when manu- section.
ally lifting heavy parts or equipment. D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
OVERUSE can cause OVERHEATING codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit. H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
FLYING SPARKS can injure. navigation, safety services, computers, and
communications equipment.
D Wear a face shield to protect eyes and face.
D Have only qualified persons familiar with
D Shape tungsten electrode only on grinder with electronic equipment perform this installation.
proper guards in a safe location wearing proper
face, hand, and body protection. D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
D Sparks can cause fires — keep flammables away. tion.
D If notified by the FCC about interference, stop using the
STATIC (ESD) can damage PC boards. equipment at once.
D Have the installation regularly checked and maintained.
D Put on grounded wrist strap BEFORE handling D Keep high-frequency source doors and panels tightly shut, keep
boards or parts. spark gaps at correct setting, and use grounding and shielding to
D Use proper static-proof bags and boxes to minimize the possibility of interference.
store, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts. ARC WELDING can cause interference.
D Keep away from pinch points such as drive D Electromagnetic energy can interfere with
rolls. sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
WELDING WIRE can injure. D Be sure all equipment in the welding area is
electromagnetically compatible.
D Do not press gun trigger until instructed to do
so. D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Do not point gun toward any part of the body,
other people, or any metal when threading D Locate welding operation 100 meters from any sensitive elec-
welding wire. tronic equipment.
D Be sure this welding machine is installed and grounded
BATTERY EXPLOSION can injure. according to this manual.
D If interference still occurs, the user must take extra measures
D Do not use welder to charge batteries or jump such as moving the welding machine, using shielded cables,
start vehicles unless it has a battery charging using line filters, or shielding the work area.
feature designed for this purpose.

OM- 253 392 Page 3

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org).
http://www.aws.org or purchased from Global Engineering Documents
Safe Practice For Occupational And Educational Eye And Face Protec-
(phone: 1-877-413-5184, website: www.global.ihs.com).
tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: www.ansi.org).
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for Welding and Cutting Containers that have Held Com- Work, NFPA Standard 51B, from National Fire Protection Association,
bustibles, American Welding Society Standard AWS A6.0, from Global Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, phone for Region 5, Chicago, is 312-353-2220, website:
from Compressed Gas Association, 14501 George Carter Way, Suite www.osha.gov).
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga- Applications Manual for the Revised NIOSH Lifting Equation, The Na-
net.com). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safety in Welding, Cutting, and Allied Processes, CSA Standard Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
W117.2, from Canadian Standards Association, Standards Sales, 5060 www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). The current from arc welding (and allied pro- welding circuit as possible.
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding 5. Connect work clamp to workpiece as close to the weld as
circuit. EMF fields may interfere with some medical implants, e.g. pace- possible.
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con- 6. Do not work next to, sit or lean on the welding power source.
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit: 7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
About Implanted Medical Devices:
cable cover.
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.

OM- 253 392 Page 4

 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2013−09
7

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on . Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
NOTE − Indique des déclarations pas en relation avec des blessures
afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.

2-2. Dangers relatifs au soudage à l’arc

le sol. Dans ces conditions, utiliser les équipements suivants,
Les symboles représentés ci-dessous sont utilisés dans ce ma- dans l’ordre indiqué : 1) un poste à souder DC à tension constante
nuel pour attirer l’attention et identifier les dangers possibles. En (à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
présence de l’un de ces symboles, prendre garde et suivre les souder AC à tension à vide réduite. Dans la plupart des situations,
instructions afférentes pour éviter tout risque. Les instructions l’utilisation d’un poste à souder DC à fil à tension constante est re-
en matière de sécurité indiquées ci-dessous ne constituent commandée. En outre, ne pas travailler seul !
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Sec- D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
tion 2-5. Lire et observer toutes les normes de sécurité. stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-
mes de sécurité).
Seul un personnel qualifié est autorisé à installer, faire fonc-
tionner, entretenir et réparer cet appareil. D Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil. D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
UNE DÉCHARGE ÉLECTRIQUE peut cordon est raccordée à une prise correctement mise à la terre.
entraîner la mort. D En effectuant les raccordements d’entrée, fixer d’abord le conduc-
Le contact d’organes électriques sous tension peut teur de mise à la terre approprié et contre-vérifier les connexions.
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
sous tension lorsque le courant est délivré à la protégez−les contre les étincelles et les pièces métalliques
sortie. Le circuit d’alimentation et les circuits inter- chaudes.
nes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode D Vérifier fréquemment le cordon d’alimentation et le conducteur de
de soudage avec du fil, le fil, le dérouleur, le bloc de mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
commande du rouleau et toutes les parties métalli- le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîn-
ques en contact avec le fil sont sous tension er la mort.
électrique. Un équipement installé ou mis à la terre
de manière incorrecte ou impropre constitue un D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
danger. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
D Ne pas toucher aux pièces électriques sous tension.
D Ne pas enrouler les câbles autour du corps.
D Porter des gants isolants et des vêtements de protection secs et
sans trous. D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la D Ne pas toucher l’électrode quand on est en contact avec la pièce,
pièce à couper ou le sol. la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
D Ne pas se servir de source électrique à courant électrique dans les
en même temps à cause de la présence d’une tension à vide dou-
zones humides, dans les endroits confinés ou là où on risque de
blée.
tomber.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
D Se servir d’une source électrique à courant électrique UNIQUE-
champ les pièces endommagées. Entretenir l’appareil conformé-
MENT si le procédé de soudage le demande. ment à ce manuel.
D Si l’utilisation d’une source électrique à courant électrique s’avère D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé. D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D D’autres consignes de sécurité sont nécessaires dans les condi-
tions suivantes : risques électriques dans un environnement D Fixer le câble de retour de façon à obtenir un bon contact métal-
humide ou si l’on porte des vêtements mouillés ; sur des structures métal avec la pièce à souder ou la table de travail, le plus près pos-
métalliques telles que sols, grilles ou échafaudages ; en position sible de la soudure.
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque D Isoler la pince de masse quand pas mis à la pièce pour éviter le
élevé de contact inévitable ou accidentel avec la pièce à souder ou contact avec tout objet métallique.
OM-253 392 Page 5
D Ne pas raccorder plus d’une électrode ou plus d’un câble de D Avoir recours à des écrans protecteurs ou à des rideaux pour
masse à une même borne de sortie de soudage. Débrancher le protéger les autres contre les rayonnements les éblouissements
câble pour le procédé non utilisé. et les étincelles ; prévenir toute personne sur les lieux de ne pas
D Utiliser une protection différentielle lors de l’utilisation d’un équi- regarder l’arc.
pement auxiliaire dans des endroits humides ou mouillés. D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
Il reste une TENSION DC NON NÉGLIGEABLE dans corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
les sources de soudage onduleur UNE FOIS chaussures hautes et une casquette.
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et LE SOUDAGE peut provoquer un
décharger les condensateurs d’alimentation selon les instructions incendie ou une explosion.
indiquées dans la partie Entretien avant de toucher les pièces. Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
LES PIÈCES CHAUDES peuvent
provoquer leur éclatement. Des étincelles peuvent
provoquer des brûlures. être projetées de l’arc de soudure. La projection d’étincelles, des
D Ne pas toucher à mains nues les parties pièces chaudes et des équipements chauds peut provoquer des
chaudes. incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
D Prévoir une période de refroidissement avant de
un surchauffement ou un incendie. Avant de commencer le soudage,
travailler à l’équipement.
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Ne pas toucher aux pièces chaudes, utiliser les
outils recommandés et porter des gants de sou- D Déplacer toutes les substances inflammables à une distance de
dage et des vêtements épais pour éviter les brûlu- 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
res. soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
LES FUMÉES ET LES GAZ peuvent sur des substances inflammables.
être dangereux. D Se protéger et d’autres personnes de la projection d’étincelles et
Le soudage génère des fumées et des gaz. Leur de métal chaud.
inhalation peut être dangereux pour votre santé. D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
D Eloigner votre tête des fumées. Ne pas respirer les fumées. fissures et des ouvertures.

D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au D Surveiller tout déclenchement d’incendie et tenir un extincteur à
niveau de l’arc pour l’évacuation des fumées et des gaz de proximité.
soudage. Pour déterminer la bonne ventilation, il est recommandé D Le soudage effectué sur un plafond, plancher, paroi ou séparation
de procéder à un prélèvement pour la composition et la quantité peut déclencher un incendie de l’autre côté.
de fumées et de gaz auxquels est exposé le personnel.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
approuvé. préparés correctement conformément à AWS F4.1 et AWS A6.0
D Lire et comprendre les fiches de données de sécurité et les instruc- (voir les Normes de Sécurité).
tions du fabricant concernant les adhésifs, les revêtements, les D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
nettoyants, les consommables, les produits de refroidissement, les peurs inflammables (vapeur d’essence, par exemple).
dégraisseurs, les flux et les métaux.
D Brancher le câble de masse sur la pièce le plus près possible de la
D Travailler dans un espace fermé seulement s’il est bien ventilé ou zone de soudage pour éviter le transport du courant sur une
en portant un respirateur à alimentation d’air. Demander toujours à longue distance par des chemins inconnus éventuels en provo-
un surveillant dûment formé de se tenir à proximité. Des fumées et quant des risques d’électrocution, d’étincelles et d’incendie.
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels. D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
S’assurer que l’air de respiration ne présente aucun danger. lées.
D Ne pas souder dans des endroits situés à proximité d’opérations D En cas de non utilisation, enlever la baguette d’électrode du porte-
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et électrode ou couper le fil à la pointe de contact.
les rayons de l’arc peuvent réagir en présence de vapeurs et for- D Porter un équipement de protection pour le corps fait d’un matériau
mer des gaz hautement toxiques et irritants. résistant et ignifuge (cuir, coton robuste, laine). La protection du
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier corps comporte des vêtements sans huile comme par ex. des
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- gants de cuir, une chemise solide, des pantalons sans revers, des
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit chaussures hautes et une casquette.
bien ventilé, et en portant un respirateur à alimentation d’air. Les D Avant de souder, retirer toute substance combustible de vos po-
revêtements et tous les métaux renfermant ces éléments peuvent ches telles qu’un allumeur au butane ou des allumettes.
dégager des fumées toxiques en cas de soudage.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
LES RAYONS DE L’ARC peuvent trace d’étincelles incandescentes ni de flammes.
provoquer des brûlures dans les D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
yeux et sur la peau. Ne pas augmenter leur puissance; ne pas les ponter.
Le rayonnement de l’arc du procédé de soudage D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
génère des rayons visibles et invisibles intense trace d’étincelles incandescentes ni de flammes.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
dans les yeux et sur la peau. Des étincelles sont projetées pendant le Ne pas augmenter leur puissance; ne pas les ponter.
soudage.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
D Porter un casque de soudage approuvé muni de verres filtrants NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
approprié pour protéger visage et yeux pour protéger votre visage extincteur à proximité.
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 D Lire et comprendre les fiches de données de sécurité et les instruc-
et Z87.1 énuméré dans les normes de sécurité).
tions du fabricant concernant les adhésifs, les revêtements, les
D Porter des lunettes de sécurité avec écrans latéraux même sous nettoyants, les consommables, les produits de refroidissement,
votre casque. les dégraisseurs, les flux et les métaux.
OM-253 392 Page 6
 DES PIECES DE METAL ou DES LES BOUTEILLES peuvent exploser
SALETES peuvent provoquer des si elles sont endommagées.
blessures dans les yeux. Les bouteilles de gaz comprimé contiennent du gaz
sous haute pression. Si une bouteille est
D Le soudage, l’écaillement, le passage de la endommagée, elle peut exploser. Du fait que les
pièce à la brosse en fil de fer, et le meulage gé- bouteilles de gaz font normalement partie du
nèrent des étincelles et des particules procédé de soudage, les manipuler avec
métalliques volantes. Pendant la période de précaution.
refroidissement des soudures, elles risquent D Protéger les bouteilles de gaz comprimé d’une chaleur excessi-
de projeter du laitier. ve, des chocs mécaniques, des dommages physiques, du lai-
D Porter des lunettes de sécurité avec écrans latéraux ou un écran tier, des flammes ouvertes, des étincelles et des arcs.
facial. D Placer les bouteilles debout en les fixant dans un support sta-
tionnaire ou dans un porte-bouteilles pour les empêcher de tom-
ber ou de se renverser.
LES ACCUMULATIONS DE GAZ D Tenir les bouteilles éloignées des circuits de soudage ou autres
risquent de provoquer des blessures circuits électriques.
ou même la mort. D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Fermer l’alimentation du gaz comprimé en cas D Une électrode de soudage ne doit jamais entrer en contact avec
de non utilisation. une bouteille.
D Veiller toujours à bien aérer les espaces confi- D Ne jamais souder une bouteille pressurisée − risque d’explosion.
nés ou se servir d’un respirateur d’adduction
d’air homologué. D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application
Les CHAMPS ÉLECTROMAGNÉTIQUES spécifique; les maintenir ainsi que les éléments associés en bon
état.
(CEM) peuvent affecter les implants mé-
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
dicaux. de la bouteille. Ne pas se tenir devant ou derrière le régulateur
lors de l’ouverture de la vanne.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à D Le couvercle du détendeur doit toujours être en place, sauf lors-
distance. que la bouteille est utilisée ou qu’elle est reliée pour usage ulté-
rieur.
D Les porteurs d’implants médicaux doivent consulter leur
D Utiliser les équipements corrects, les bonnes procédures et suf-
médecin et le fabricant du dispositif avant de s’approcher de la
fisamment de personnes pour soulever et déplacer les bouteil-
zone où se déroule du soudage à l’arc, du soudage par points, du les.
gougeage, de la découpe plasma ou une opération de chauffage
par induction. D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sé-
LE BRUIT peut endommager l’ouïe. curité.

Le bruit des processus et des équipements peut

affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

D Suivre les consignes du Manuel des applications pour l’équation

Risque D’INCENDIE OU de levage NIOSH révisée (Publication Nº94–110) lors du levage
D’EXPLOSION. manuelle de pièces ou équipements lourds.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables. L’EMPLOI EXCESSIF peut
D Ne pas installer l’appareil à proximité de pro- SURCHAUFFER L’ÉQUIPEMENT.
duits inflammables. D Prévoir une période de refroidissement ; res-
D Ne pas surcharger l’installation électrique − s’assurer que pecter le cycle opératoire nominal.
l’alimentation est correctement dimensionnée et protégée avant D Réduire le courant ou le facteur de marche
de mettre l’appareil en service. avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures. LES ÉTINCELLES PROJETÉES
D Utiliser l’anneau de levage uniquement pour peuvent provoquer des blessures.
soulever l’appareil, NON PAS les chariots, les D Porter un écran facial pour protéger le visage et
bouteilles de gaz ou tout autre accessoire. les yeux.
D Utiliser un équipement de levage de capacité suffisante pour lever D Affûter l’électrode au tungstène uniquement à la
l’appareil. meuleuse dotée de protecteurs. Cette
manœuvre est à exécuter dans un endroit sûr
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer lorsque l’on porte l’équipement homologué de
que les fourches sont suffisamment longues pour dépasser du protection du visage, des mains et du corps.
côté opposé de l’appareil.
D Les étincelles risquent de causer un incendie − éloigner toute sub-
D Tenir l’équipement (câbles et cordons) à distance des véhicules stance inflammable.
mobiles lors de toute opération en hauteur.
OM-253 392 Page 7
 LES CHARGES ÉLECTROSTATI- LE RAYONNEMENT HAUTE
QUES peuvent endommager les cir- FRÉQUENCE (H.F.) risque de
cuits imprimés. provoquer des interférences.
D Établir la connexion avec la barrette de terre D Le rayonnement haute fréquence (H.F.) peut
avant de manipuler des cartes ou des pièces. provoquer des interférences avec les équi-
D Utiliser des pochettes et des boîtes antista- pements de radio−navigation et de com-
tiques pour stocker, déplacer ou expédier des munication, les services de sécurité et les ordi-
cartes de circuits imprimes. nateurs.
D Demander seulement à des personnes qualifiées familiarisées
Les PIÈCES MOBILES peuvent avec des équipements électroniques de faire fonctionner l’instal-
causer des blessures. lation.
D Ne pas s’approcher des organes mobiles. D L’utilisateur est tenu de faire corriger rapidement par un électri-
cien qualifié les interférences résultant de l’installation.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande. D Si le FCC signale des interférences, arrêter immédiatement l’ap-
pareil.
LES FILS DE SOUDAGE peuvent D Effectuer régulièrement le contrôle et l’entretien de l’installation.
provoquer des blessures. D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une dis-
D Ne pas appuyer sur la gâchette avant d’en tance correcte et utiliser une terre et un blindage pour réduire les
avoir reçu l’instruction. interférences éventuelles.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en
engageant le fil de soudage. LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’EXPLOSION DE LA BATTERIE D L’énergie électromagnétique risque de
peut provoquer des blessures. provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
D Ne pas utiliser l’appareil de soudage pour l’équipement commandé par ordinateur tel que
charger des batteries ou faire démarrer les robots.
des véhicules à l’aide de câbles de démarrage,
D Veiller à ce que tout l’équipement de la zone de soudage soit
sauf si l’appareil dispose d’une fonctionnalité
compatible électromagnétiquement.
de charge de batterie destinée à cet usage.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
Les PIÈCES MOBILES peuvent soudage aussi courts que possible, les grouper, et les poser
causer des blessures. aussi bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipe-
D S’abstenir de toucher des organes mobiles tels ment électronique sensible.
que des ventilateurs.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
D Maintenir fermés et verrouillés les portes, conformément à ce mode d’emploi.
panneaux, recouvrements et dispositifs de
D En cas d’interférences après avoir pris les mesures précéden-
protection. tes, il incombe à l’utilisateur de prendre des mesures supplé-
D Lorsque cela est nécessaire pour des travaux d’entretien et de mentaires telles que le déplacement du poste, l’utilisation de câ-
dépannage, faire retirer les portes, panneaux, recouvrements bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
ou dispositifs de protection uniquement par du personnel qua- teurs dans la zone de travail.
lifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’instal-
lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.

OM-253 392 Page 8

2-4. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du
fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent
dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres
formations congénitales et, dans certains cas, des cancers. problèmes de procréation. Se laver les mains après
(Code de santé et de sécurité de Californie, chapitre 25249.5 utilisation.
et suivants)

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org).
http://www.aws.org or purchased from Global Engineering Documents
Safe Practice For Occupational And Educational Eye And Face Protec-
(phone: 1-877-413-5184, website: www.global.ihs.com).
tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: www.ansi.org).
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for Welding and Cutting Containers that have Held Com- Work, NFPA Standard 51B, from National Fire Protection Association,
bustibles, American Welding Society Standard AWS A6.0, from Global Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, phone for Region 5, Chicago, is 312-353-2220, website:
from Compressed Gas Association, 14501 George Carter Way, Suite www.osha.gov).
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga- Applications Manual for the Revised NIOSH Lifting Equation, The Na-
net.com). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safety in Welding, Cutting, and Allied Processes, CSA Standard Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
W117.2, from Canadian Standards Association, Standards Sales, 5060 www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs 3. Ne pas courber et ne pas entourer les câbles autour de votre
électromagnétiques (CEM) à certains endroits. Le courant issu d’un corps.
soudage à l’arc (et de procédés connexes, y compris le soudage par 4. Maintenir la tête et le torse aussi loin que possible du matériel du
points, le gougeage, le découpage plasma et les opérations de circuit de soudage.
chauffage par induction) crée un champ électromagnétique (CEM)
5. Connecter la pince sur la pièce aussi près que possible de la
autour du circuit de soudage. Les CEM peuvent créer des interférences soudure.
avec certains implants médicaux comme des stimulateurs cardiaques.
Des mesures de protection pour les porteurs d’implants médicaux 6. Ne pas travailler à proximité d’une source de soudage, ni
doivent être prises: Limiter par exemple tout accès aux passants ou s’asseoir ou se pencher dessus.
procéder à une évaluation des risques individuels pour les soudeurs. 7. Ne pas souder tout en portant la source de soudage ou le
Tous les soudeurs doivent appliquer les procédures suivantes pour dévidoir.
minimiser l’exposition aux CEM provenant du circuit de soudage: En ce qui concerne les implants médicaux :
1. Rassembler les câbles en les torsadant ou en les attachant avec Les porteurs d’implants doivent d’abord consulter leur médecin avant
du ruban adhésif ou avec une housse. de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc-
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les tion. Si le médecin approuve, il est recommandé de suivre les
câbles d’un côté et à distance de l’opérateur. procédures précédentes.

OM-253 392 Page 9

OM-253 392 Page 10
 SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Safe1 2012−05

Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation − keep hands
and metal objects away.

Safe95 2012−05

Beware of electric shock from wiring.

Safe94 2012−08

When power is applied failed parts can explode or cause other parts to explode.

Safe26 2012−05

Become trained and read the instructions before working on the

machine or welding.

Safe40 2012−05

V Hazardous voltage remains on input capacitors after power is turned

V off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor
voltage, and be sure it is near 0 before touching any parts.
>5min V Safe43 2012−05

Notes

OM-253 392 Page 11

3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.

A Amperage
Direct Current
(DC)
Alternating
Current (AC) V Voltage

Gas Input Circuit Breaker I2 Rated Welding

Current
Increase

U1 Primary Voltage Positive Negative

Shielded Metal Arc
Welding (SMAW)

Gas Tungsten Arc

Welding (GTAW) /
Tungsten Inert Gas
(TIG) Welding
U2 Conventional
Load Voltage
Line Connection
Hz Hertz

Single Phase

IP U0
Static Frequency
Internal Protection Rated No Load Gas Metal Arc
Converter-
Rating Voltage (OCV) Welding (GMAW)
Transformer-
Rectifier

X S
Suitable for Some
Input Power Or In-
Single Phase Duty Cycle Hazardous
put Voltage
Locations

Gas Metal Arc Gas Tungsten Arc Wire Feed Spool

Remote Welding (GMAW) Welding (GTAW) Gun / MIG Alumin-
MIG / Gun Control Torch um

Self-Shielded Flux
Shielded Metal Arc Lift Arc (GTAW)
Cored Arc Weld-
(SMAW) Stick TIG / Remote
ing (SMAW)

Notes

OM-253 392 Page 12

 . A complete Parts List is available at www.MillerWelds.com

SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the side. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Unit Specifications For MIG (GMAW)

. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-9, 5-11, and 5-12 for information
on connecting input power.

Maximum Open- Amperes Input at Rated

Input Rated Welding Amperage
Circuit Voltage Load Output, 50/60 Hz,
Voltage Output Range
DC Single-Phase
110 A @ 19.5 Volts DC, 20%
Duty Cycle 22.4
30 − 140 90
75 A @ 17.75 Volts DC, 14.6*
120 VAC 100% Duty Cycle*
Solid/Stainless Flux Cored Wire Feed Speed Range
Wire Type
And Dia .023 - .035 in. .030 - .035 in.
70 − 425 IPM (1.75 − 10.8 m/min)
(0.6 - 0.8 mm) (0.8 - 0.9 mm)
150 A @ 21.5 Volts DC, 20%
Duty Cycle 17.5
30 − 200 90
120 A @ 20 Volts DC, 100% 13.1*
230 VAC Duty Cycle*
Solid/Stainless Flux Cored Wire Feed Speed Range
Wire Type
And Dia .023 − .035 in. .030 − .045 in.
70 − 425 IPM (1.75 − 10.8 m/min)
(0.6 − 0.9 mm) (0.8 − 1.2 mm)
* CSA Rating

4-3. Unit Specifications For TIG (GTAW)

. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-9, 5-11, and 5-12 for information
on connecting input power.

Maximum Open- Amperes Input at Rated

Input Rated Welding Amperage
Circuit Voltage Load Output, 50/60 Hz,
Voltage Output Range
DC Single-Phase
150 A @ 16 Volts DC, 30%
Duty Cycle 27.0
120 VAC 5 − 150 90
70 A @ 13 Volts DC, 100% 10.5*
Duty Cycle*
150 A @ 16 Volts DC, 30%
Duty Cycle 13.8
230 VAC 5 − 150 90
100 A @ 14 Volts DC, 100% 15.9*
Duty Cycle*
* CSA Rating

OM-253 392 Page 13

 . A complete Parts List is available at www.MillerWelds.com

4-4. Unit Specifications For Stick (SMAW)

. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-9, 5-11, and 5-12 for information
on connecting input power.

Maximum Open- Amperes Input at Rated

Input Rated Welding Amperage
Circuit Voltage Load Output, 50/60 Hz,
Voltage Output Range
DC Single-Phase
100 A @ 24 Volts DC, 35%
Duty Cycle 23.8
120 VAC 20 − 100 90
70 A @ 22.8 Volts DC, 100% 16.5*
Duty Cycle*
150 A @ 26 Volts DC, 30%
Duty Cycle 20.8
230 VAC 20 − 150 90
100 A @ 24 Volts DC, 100% 12.7*
Duty Cycle*
* CSA Rating

4-5. Dimensions And Weight

9-3/4 in.
(248 mm)

Weight
29 lb (13.2 kg)

14-1/2 in.
(368 mm)

17 in.
(432 mm)

253 921-B

Notes

OM-253 392 Page 14

 . A complete Parts List is available at www.MillerWelds.com

4-6. Duty Cycle And Overheating For MIG

Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops. Wait
200 fifteen minutes for unit to cool.
Reduce amperage or duty cycle
180 before starting to weld again.
230VAC
NOTICE − Exceeding duty cycle
160 can damage unit and void warranty.

140
Output Amperes

120
120VAC
100

80

60

40

20

0
10 20 50 100
% Duty Cycle

120V Input

20% Duty Cycle At 110A 100% Duty Cycle At 75A

2 Minutes Welding 8 Minutes Resting Continuous

Welding

230V Input

20% Duty Cycle At 150A 100% Duty Cycle At 120A

2 Minutes Welding 8 Minutes Resting Continuous

Welding

Overheating

0
A or V

15
OR
Reduce Duty Cycle
Minutes

duty1 4/95 − Ref. Duty Cycle Charts

OM-253 392 Page 15

 . A complete Parts List is available at www.MillerWelds.com

4-7. Duty Cycle And Overheating For TIG

Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops. Wait
200 fifteen minutes for unit to cool.
Reduce amperage or duty cycle
180 before starting to weld again.
230V & 120V 20A NOTICE − Exceeding duty cycle
160 can damage unit and void warranty.

140

120
Output Amperes

100

80

60
120V 15A
40

20

0
10 30 50 100
% Duty Cycle

120V Input

30% Duty Cycle At 150A

100% Duty Cycle At 75A

3 Minutes Welding 7 Minutes Resting Continuous

Welding

230V Input

30% Duty Cycle At 150A 100% Duty Cycle At 100A

Continuous
3 Minutes Welding 7 Minutes Resting Welding

Overheating

0
A or V

15
OR
Reduce Duty Cycle
Minutes

duty1 4/95 − Ref. Duty Cycle Charts

OM-253 392 Page 16

 . A complete Parts List is available at www.MillerWelds.com

4-8. Duty Cycle And Overheating For Stick

Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops. Wait
fifteen minutes for unit to cool.
200 Reduce amperage or duty cycle
before starting to weld again.
180
NOTICE − Exceeding duty cycle
160 230V can damage unit and void warranty.

140
Output Amperes

120
120V 20A
100

80

60
120V 15A
40

20

0
10 30 50 100
% Duty Cycle

120V Input

35% Duty Cycle At 100A

100% Duty Cycle At 70A

Continuous
3-1/2 Minutes Welding 6-1/2 Minutes Resting
Welding

230V Input

30% Duty Cycle At 150A 100% Duty Cycle At 100A

Continuous
3 Minutes Welding 7 Minutes Resting Welding

Overheating

0
A or V

15
OR
Reduce Duty Cycle
Minutes

duty1 4/95 − Ref. Duty Cycle Charts

OM-253 392 Page 17

 . A complete Parts List is available at www.MillerWelds.com

SECTION 5 − INSTALLATION
5-1. Selecting A Location
! Do not move or operate unit
where it could tip.

Movement, Location, And Airflow

2

18 in.
(460 mm)

! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1 Lifting Handle
Use handle to lift unit.
2 Line Disconnect Device
Locate unit near correct input
power supply.

18 in.
(460 mm)
loc_multi200 - 253 921-B

5-2. Stick Welding Connections

! Turn off unit and disconnect
input power before making
connections.
1 Positive Weld Output
Receptacle
2 Negative Weld Output
Receptacle
3 Stick Electrode Holder And
Cable
4 Work Clamp And Cable
Connect stick electrode holder
1 cable to the positive weld output
receptacle, and connect work
clamp to negative weld output
receptacle.
2
Ensure all connections are tight.
3

Ref. 254 251-B

OM-253 392 Page 18

 . A complete Parts List is available at www.MillerWelds.com

5-3. TIG Welding Connections DCEN (Direct Current Electrode Negative)

! Turn off unit and disconnect
input power before making
connections.
1 Positive Weld Output
Receptacle
2 Negative Weld Output
Receptacle
3 TIG Torch And Cable
4 Work Clamp And Cable
1
Connect TIG torch cable to the
4 negative weld output receptacle
and connect work clamp to positive
weld output receptacle.
Ensure all connections are tight.
2 5 Foot Control
6 Finger Tip Control
7 Remote Control Cable
8 Six Pin Remote Control
Receptacle
3
Route control cable through MIG
gun hole.
Connect foot control or finger tip
control to six pin remote control
receptacle.
9 TIG Shielding Gas
Connection
Use Argon gas for TIG welding (see
Section 5-7).
5
8

Ref. 254 251-B / Ref. 254 249-C / Ref. 254 247-B

OM-253 392 Page 19

 . A complete Parts List is available at www.MillerWelds.com

5-4. Process/Polarity Table

Cable Connections
Process Polarity
Wire Drive Assembly Cable Work Cable
GMAW − Solid wire with shielding gas DCEP − Reverse polarity Connect to positive (+) Connect to negative (−)
output receptacle output receptacle
FCAW − Self-shielding wire − no DCEN − Straight Polarity Connect to negative (−) Connect to positive (+)
shielding gas output receptacle output receptacle

5-5. Wire Welding Connections

1 1

2 2

3
3
4 4
MIG − DCEP
(Direct Current Electrode Positive) Flux-Cored − DCEN
(Direct Current Electrode Negative)

Ref. 254 252-B / Ref. 254 249-C / Ref. 254 247-B

! Turn off unit and disconnect input 5 Gun End Connect plug on end of cable to four pin
power before making connections. Connect gun end to drive assembly (see receptacle inside unit.
1 Positive Weld Output Receptacle Section 5-6).
8 MIG Shielding Gas Connection
2 Negative Weld Output Receptacle 6 Trigger Control Cable
7 Four Pin Trigger Control Cable Use 75/25 mix or CO2 shielding gas for
3 Wire Drive Assembly Cable Receptacle solid wire. Use Argon shielding gas for
4 Work Clamp And Cable Route trigger control cable through MIG aluminum wire with spool gun (see Section
Ensure all connections are tight. gun hole. 5-7).

OM-253 392 Page 20

 . A complete Parts List is available at www.MillerWelds.com

5-6. Wire Gun Connection Inside Unit

3 4

2
1
Ref. 254 249-C

1 Gun Securing Knob Loosen knob. Insert end of gun through 6 Four Pin Trigger Control Cable
opening in front panel until gun end Receptacle
2 Gun Block bottoms against gun block. Tighten Route trigger control cable through MIG
knob. gun hole.
3 Gun Outlet Wire Guide
Connect plug on end of cable to four pin
4 Gun End 5 Trigger Control Cable receptacle inside unit.

. Be sure that gun end is tight against drive assembly.

4 4

Correct Incorrect

Ref. 801 987

OM-253 392 Page 21

 . A complete Parts List is available at www.MillerWelds.com

5-7. Connecting Shielding Gas Supply

Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
1 Cap
2 Cylinder Valve
Remove cap, stand to side of valve,
and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.
1 3 Cylinder
4 Regulator/Flowmeter
Install so face is vertical.
5 Regulator/Flowmeter Gas
2 Hose Connection
6 Welding Power Source CO2
And Mixed Gas Hose
Connection
3
7 Welding Power Source Argon
Gas Hose Connection
1
Mixed Gas Connect gas hose between
regulator/flowmeter gas hose
1 connection, and the appropriate
2 fitting for the gas type on rear of
welding power source.
9
10 8 Flow Adjust
2
3 Typical flow rate for CO2 shielding
gas and MIG (GMAW) welding is 15
to 30 cfh (cubic feet per hour) and
3 mixed gas is 25 to 45 cfh.
Argon Gas Typical flow rate for Argon shielding
gas and TIG (GTAW) welding is 15
CO2 Gas to 25 cfh and aluminum MIG
4 (GMAW) welding is 35 to 45 cfh.
4 Check wire manufacturer’s
8 8 recommended flow rate.
9 CO2 Adapter (Customer
5 5 Supplied)
10 O-Ring (Customer Supplied)
Install adapter with O-ring between
regulator/flowmeter and CO2
cylinder.

7
6

MIG TIG

Tools Needed:

Ref. 804 654-A / 254 247-B

OM-253 392 Page 22

 . A complete Parts List is available at www.MillerWelds.com

5-8. Multi−Voltage Plug (MVP) Connection

Selecting Plug

2
1
3

! Do not cut off power cord con-

nector and rewire. The power
cord connector and plugs will
work with standard NEMA re-
ceptacles. Modifying power
cord, connector, and plugs will
6 void product warranty.

Connecting Plug To Power Cord

Selecting Plug 4 Plug − NEMA Type 5−20P (Optional) Connecting Plug To Power Cord
1 Power Cord Connector From 5 Receptacle − NEMA Type 5−20R
Welding Power Source (Customer Supplied) Align arrow on plug with arrow on power
6 Plug − NEMA Type 6−50P cord connector. Push together.
Select plug for power supply receptacle
available at site. Not all plugs shown are 7 Receptacle − NEMA Type 6−50R
provided as standard with unit. (Customer Supplied) Tighten threaded collar. As threaded collar
is tightened, push plug onto adapter until
2 Plug − NEMA Type 5−15P
! Follow electrical service guide for
collar is completely tight.
230 VAC in Section 5-9. Do not use
3 Receptacle − NEMA Type 5−15R plug rating to size branch circuit
(Customer Supplied) protection. Connect plug to receptacle.

MVP Plug1 2010−10 / Ref. 803 812-C

OM-253 392 Page 23

 . A complete Parts List is available at www.MillerWelds.com
5-9. Electrical Service Guide Elec Serv 2014−01

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
. Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
be available.

50/60 Hz 230 50/60 Hz 120

Single Phase Volts AC
Input Voltage (V) 230
A 15 or 20
Input Amperes (A) At Rated Output 17.7 ampere
Max Recommended Standard Fuse Rating In Amperes 1 individual
branch circuit
Time-Delay Fuses 2 20 protected by
time-delay
Normal Operating Fuses 3 25 fuses or
4 circuit breaker
Min Input Conductor Size In AWG 14
is required.
65
Max Recommended Input Conductor Length In Feet (Meters) See Section
(20)
5-11
Min Grounding Conductor Size In AWG 4 14

Reference: 2014 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.

5-10. Extension Cord Data

Input Power
Input Voltage Phase Hertz Conductor Size Max. Cord Length

120 V 1 50/60 14 AWG 24 ft (7 m)

230 V 1 50/60 14 AWG 65 ft (20 m)

OM-253 392 Page 24

 . A complete Parts List is available at www.MillerWelds.com

5-11. Connecting 115 Volt Input Power

! Installation must meet all
National and Local Codes − have
only qualified persons make this
installation.
! Special installation may be
required where gasoline or volatile
liquids are present − see NEC
Article 511 or CEC Section 20.
NOTICE − The Auto-Line circuitry in this
unit automatically links the power source
to the primary voltage being applied, either
115 or 230 VAC.
See rating label on unit and check input
voltage available at site.
For 115 volts AC input power, a 15 or 20
ampere individual branch circuit protected
by time-delay fuses or circuit breaker is
required.
1 Multi-Voltage Plug And Power Cord
Connector (NEMA Type 5−15P Plug
Shown)
For multi−voltage plug connections, see
Section 5-8.
1 Plug From Unit
2 Receptacle − NEMA Type 5−15R
(Customer Supplied)

1 2

Input6 2011−03 253 921-B / Ref. 805 474-A

OM-253 392 Page 25

 . A complete Parts List is available at www.MillerWelds.com

5-12. Connecting 1-Phase Input Power For 230 VAC

3 =GND/PE Earth Ground

L1
5
L2
6

L2 L1

230 VAC, 1

Tools Needed:

input4 2012-05 − 803 766-C / Ref. 802 443-A / 253 921-B

OM-253 392 Page 26

 . A complete Parts List is available at www.MillerWelds.com

5-12. Connecting 1-Phase Input Power For 230 VAC (Continued)

! Installation must meet all National and primary voltage being applied, either 115 or Connect green or green/yellow grounding
Local Codes − have only qualified per- 230 VAC. conductor to disconnect device grounding
sons make this installation. terminal first.
See rating label on unit and check input volt-
! Disconnect and lockout/tagout input age available at site. Connect input conductors L1 and L2 to dis-
power before connecting input con- connect device line terminals.
1 Input Power Cord
ductors from unit. Follow established 7 Over-Current Protection
procedures regarding the installation 2 Disconnect Device (switch shown in the
OFF position) Select type and size of over-current
and removal of lockout/tagout protection using Section 5-9 (fused
devices. 3 Disconnect Device Grounding Terminal disconnect switch shown).
! Always connect green or green/yellow 4 Disconnect Device Line Terminals 8 Receptacle (NEMA 6-50R)
conductor to supply grounding termi- 5 Black And White Input Conductor (L1 Customer Supplied
nal first, and never to a line terminal. And L2) Close and secure door on disconnect device.
NOTICE − The Auto-Line circuitry in this unit 6 Green Or Green/Yellow Grounding Remove lockout/tagout device, and place
automatically links the power source to the Conductor switch in the On position.

input4 2012−05 − 803 766-C

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-253 392 Page 27

 . A complete Parts List is available at www.MillerWelds.com

5-13. Installing Wire Spool And Adjusting Hub Tension

1 Wire Spool
2 Retaining Nut [For 8 in. (203
mm) Spool Only]

Tools Needed:

1/2 in.

Installing 4 in. (102 mm) Wire Spool

When a slight force is needed
to turn spool, tension is set.

Installing 8 in. (203 mm) Wire Spool

Adapter used with 8 in.
(203 mm) spool only.

When a slight force is needed

to turn spool, tension is set.

Align locking hole in

spool with locking
pin on spool hub.

Retaining ring used with 8 in.

(203 mm) spool only.

Ref. 254 253-C / 803 012 / 803 013 -B / Ref. 802 444-C

OM-253 392 Page 28

 . A complete Parts List is available at www.MillerWelds.com
5-14. Threading Welding Wire
1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll
6 Outlet Wire Guide
4 7 Gun Conduit Cable
Lay gun cable out straight.

Tools Needed:

1 2 3 5 6

. Hold wire tightly to keep it

from unraveling.

6 in.
(150 mm)

Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.

. Use pressure indicator scale to set a desired

Tighten drive roll pressure. Begin with a setting of 2.
If necessary, make additional adjustments
after trying this initial setting.
1 Pressure
2 Indicator
3 Scale
4

Close and tighten pressure Remove gun nozzle and contact tip. Turn On.
assembly, and let go of wire.

Tighten

1
2
3
WOOD 4

Press gun trigger until wire Feed wire to check drive roll pressure. Cut off wire. Close
comes out of gun. Reinstall Tighten knob enough to prevent slipping. and latch door.
contact tip and nozzle
Ref. 254 253-C / 254 249-C / 801 083 / Ref. 800 924-D

OM-253 392 Page 29

 . A complete Parts List is available at www.MillerWelds.com

SECTION 6 − OPERATION
6-1. Controls
1 Process Select Knob
Turn knob to select the desired
welding process.
2 Auto-Set Button
Press button to turn Auto-Set On or
Off.
3 Wire/Rod/Tungsten Buttons
Press the Plus (+) or Minus (−)
button to select the size of wire, rod,
or tungsten for the selected
process.

. When MIG Aluminum process

is selected, Wire/Rod/Tung-
sten buttons are used to select
type of spool gun being used.
4 Material Thickness Buttons
Press the Plus (+) or Minus (−)
button to select material thickness
2 for the selected process.
5 Display
1
6 Adjustment Knob
7 Power Switch
Use switch to turn unit On or Off.

4
3

6
6

Rear
View

Ref. 249 632-E / 253 923-B

OM-253 392 Page 30

 . A complete Parts List is available at www.MillerWelds.com

6-2. Weld Parameter Chart

Ref. 252 671-F

OM-253 392 Page 31

 . A complete Parts List is available at www.MillerWelds.com

6-3. Entering Setup Menu

1 Wire/Rod/Tungsten Minus (−)
Button
2 Material Thickness Plus (+)
Button
3 Display
When unit is turned off, press and
hold Wire/Rod/Tungsten Minus (−)
button and Material Thickness Plus
(+) button simultaneously.
Turn unit power on.
When Display shows MULTIMATIC
200 setup screen, release the two
buttons simultaneously.
The contrast adjustment screen
should be displayed.

1 2

Ref. 249 632-E

OM-253 392 Page 32

 . A complete Parts List is available at www.MillerWelds.com

6-4. Adjusting Display Contrast (Menu 1 Of 10)

1 Adjustment Knob
2 Material Thickness Plus (+)
Button
Follow instructions in Section 6-3 to
enter the setup menu.
The Display Contrast should now
appear on the display.
To adjust display contrast, turn
either Adjustment knob.
Cycle through menu items using
the Material Thickness Plus (+) but-
ton or cycle unit power to save set-
tings and exit menu.
Cycle unit power before welding
to complete initialization process.

1
1

Ref. 249 632-E

6-5. Calibrating Drive Motor (Menu 2 Of 10)

. The unit’s internal drive motor is calibrated at the factory. No calibration is needed unless drive motor or user interface board is changed. Contact
nearest factory authorized Service Agent or Miller Electric Mfg. Co. Service department.
OM-253 392 Page 33
 . A complete Parts List is available at www.MillerWelds.com

6-6. Calibrating Spoolmate 100 Or Spoolmate 150 (Menu 3 Of 10)

1 Material Thickness Plus (+)
Button
2 Left Adjustment Knob
3 Right Adjustment Knob
. Spoolmate 100 and 150 drive
motors are unique to this weld-
ing power source. Motor calib-
ration is necessary any time a
different Spoolmate is connec-
ted to the Multimatic 200.
Connect Spoolmate to unit. Cut
wire flush at nozzle.
Follow instructions in Section 6-3 to
enter the setup menu.
Press Material Thickness Plus (+)
button twice after entering setup to
enter the Spoolmate Calibration
menu.
To perform a Spoolmate calibration
24 in. runout test at 100 ipm, turn left
Adjustment knob and verify that a
(n) check mark appears next to
100 IPM. Be sure that wire is cut
flush at nozzle, then trigger the
Spoolmate.
Spoolmate will feed approximately
24 in. of wire through gun.
1 Cut wire flush at nozzle and meas-
ure run-out.
If wire is not 24 inches long, use left
Adjustment knob to increase or de-
crease the length of the run-out and
repeat the test.
To perform a Spoolmate calibration
24 in. runout test at 300 ipm, turn
right Adjustment knob and verify
that a (n) check mark appears next
to 300 IPM. Be sure that wire is cut
flush at nozzle, then trigger the
Spoolmate.
Spoolmate will feed approximately
24 in. of wire through gun.
Cut wire flush at nozzle and meas-
ure run-out.
2
3 If wire is not 24 inches long, use
right Adjustment knob to increase
or decrease the length of the
run-out and repeat the test.
Cycle through menu items using
the Material Thickness Plus (+) but-
ton or cycle unit power to save set-
tings and exit menu.
Cycle unit power before welding
to complete initialization process.

Tools Needed:

Ref. 249 632-E

OM-253 392 Page 34

 . A complete Parts List is available at www.MillerWelds.com

6-7. Enable/Disable Auto−Cratert (Menu 4 Of 10)

1 Adjustment Knob
2 Material Thickness Plus (+)
Button
Follow instructions in Section 6-3 to
enter the setup menu.
Press Material Thickness Plus (+)
button three times after entering
setup to enter the Auto−Crater fea-
ture menu.

. Auto−Crater is disabled by
default.
Rotate adjustment knob clockwise
to enable Auto−Crater.
Rotate adjustment knob counter-
clockwise to disable Auto−Crater.
Cycle through menu items using
the Material Thickness Plus (+) but-
ton or cycle unit power to save set-
tings and exit menu.
Cycle unit power before welding
to complete initialization process.

1
1

Ref. 249 632-E

OM-253 392 Page 35

 . A complete Parts List is available at www.MillerWelds.com

6-8. Viewing Burn-In Information (Menu 5 Of 10)

. Burn-In information is for factory and service use only.
Follow instructions in Section 6-3 to enter the setup menu.
Press Material Thickness Plus (+) button four times after entering setup to enter the Burn-In information screen.
Burn-In information displays electrical information unique to the unit.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.
Cycle unit power before welding to complete initialization process.

6-9. Viewing Software Information (Menu 6 Of 10)

. Software information is for factory and service use only.
Follow instructions in Section 6-3 to enter the setup menu.
Press Material Thickness Plus (+) button five times after entering setup to enter the Software information screen.
Software information displays software information unique to the unit.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.
Cycle unit power before welding to complete initialization process.

6-10. Viewing Primary Power Information (Menu 7 Of 10)

. Primary Power information is for factory and service use only.
Follow instructions in Section 6-3 to enter the setup menu.
Press Material Thickness Plus (+) button six times after entering setup to enter the Primary Power Logs screen.
Primary Power Logs screen displays unit power on time.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.
Cycle unit power before welding to complete initialization process.

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-253 392 Page 36

 . A complete Parts List is available at www.MillerWelds.com

6-11. Viewing Process Logs (Menu 8 Of 10)

1 Material Thickness Plus (+)
Button
2 Process Select Knob
Follow instructions in Section 6-3 to
enter the setup menu.
Press Material Thickness Plus (+)
button seven times after entering
setup to enter the Process Logs
screen.
Process Logs screen displays
manual minutes, Auto-Set minutes,
weld cycles, and Auto-Set cycles
for the selected process.
To view other processes, use the
Process Select knob to select the
desired weld process.
Cycle through menu items using
the Material Thickness Plus (+) but-
ton or cycle unit power to save set-
tings and exit menu.
Cycle unit power before welding
to complete initialization process.

Ref. 249 632-E

OM-253 392 Page 37

 . A complete Parts List is available at www.MillerWelds.com

6-12. Viewing Error Logs (Menu 9 Of 10)

1 Material Thickness Plus (+)
Button
Follow instructions in Section 6-3 to
enter the setup menu.
Press Material Thickness Plus (+)
button eight times after entering
setup to enter the Process Logs
screen.
Error Logs screen displays unit
over-temperature errors, shorted
output errors, shorted trigger er-
rors, input voltage errors, and input
current errors.
Cycle through menu items using
the Material Thickness Plus (+) but-
ton or cycle unit power to save set-
tings and exit menu.
Cycle unit power before welding
to complete initialization process.

Ref. 249 632-E

OM-253 392 Page 38

 . A complete Parts List is available at www.MillerWelds.com

6-13. Performing A Factory Reset (Menu 10 Of 10)

1 Material Thickness Plus (+)
Button
2 Auto-Set Button
. A Factory Reset will reset the
primary log data, process log
data, and error log data. Con-
trast settings, motor calibration
settings, Spoolmate Calibra-
tion settings, Burn-In informa-
tion, and Software information
will all be retained.
Follow instructions in Section 6-3 to
enter the setup menu.
Press Material Thickness Plus (+)
button nine times after entering
setup to enter the Factory Reset
screen.
To perform a Factory Reset, press
the Auto-Set button. To exit this
screen without performing a factory
reset, press the Material Thickness
Plus (+) button.
Cycle unit power before welding
to complete initialization process.
2

Ref. 249 632-E

OM-253 392 Page 39

 . A complete Parts List is available at www.MillerWelds.com

SECTION 7 − MAINTENANCE &TROUBLESHOOTING

7-1. Routine Maintenance

! Disconnect power . Maintain more often

before maintaining. during severe conditions.

n = Check Z = Change ~ = Clean l = Replace Reference

* To be done by Factory Authorized Service Agent

Every
3
Months
l Damaged Or Unreadable l Repair Or Replace
Labels Cracked Weld Cable

Every OR
6
Months
~ Inside Unit ~ Clean Drive Rolls

7-2. Overload Protection

1 Supplementary Protector CB1
CB1 protects unit from overload. If
CB1 opens, unit shuts down.
Reset supplementary protector.

253 923-B

OM-253 392 Page 40

 . A complete Parts List is available at www.MillerWelds.com

7-3. Changing Drive Roll Or Wire Inlet Guide

1 Inlet Wire Guide
Remove guide by pressing on
barbed area or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole from
rear until it snaps in place.
2 Drive Roll
1 The drive roll includes three
different sized grooves. The text
aligned with the drive roll retaining
pin indicates the selected groove
(see Section 5-14).
3 Retaining Pin
2
To secure drive roll, locate open slot
and push drive roll completely over
retaining pin, then rotate drive roll to
3 desired slot.
.030 Groove
.024 Groove .030/.035 VK Groove

267 299-A

7-4. Error Messages

Message Error Remedy

NETWORK 1 ERROR The two microcontrollers on the control board are no Cycle the power to clear this error. If this error
longer communicating. persists after a power cycle, contact Miller Electric
Mfg. Co. service department.

NETWORK 2 ERROR The microcontroller on the user interface board is Cycle the power to clear this error. If this error
no longer communicating with the microcontroller on persists after a power cycle, contact Miller Electric
the control board. Mfg. Co. service department.

CABLE ERROR The microcontroller on the user interface board is Connect the wire drive assembly cable to either the
no longer communicating with the microcontroller on positive or negative stud, or select a different
the control board. process.

A process that requires a welding gun to not be Remove the wire drive assembly cable to either the
attached to the internal motor is selected, but the positive or negative stud, or select a different
wire drive assembly cable is attached to either the process.
positive or negative stud of the power source.

OVERTEMP The internal temperature of the unit has exceeded Wait for the unit to cool down. If the fan is not
the maximum limit. running, contact Miller Electric Mfg. Co. service
department.

SHORTED OUTPUT ERROR The unit had determined that the welding gun has Once the trigger has been released, the error will
become shorted to the workpiece and turned off the clear.
output.

ROD STUCK ERROR The unit had determined that the stick welding rod Remove the stick welding rod from the workpiece
has become stuck in the welding puddle and turned and the output will turn back on after about 1
off the output. second.

SHORTED 4-PIN TRIGGER The 4-pin trigger has been held down on power up, Release the 4-pin trigger.
ERROR or the trigger has been held too long without
initiating an arc.

OM-253 392 Page 41

 . A complete Parts List is available at www.MillerWelds.com

Message Error Remedy

SHORTED 6-PIN REMOTE The 6-pin remote has been held down on power Release the 6-pin remote.
ERROR up, or the remote has been held too long without
initiating an arc.

BRIDGE CURRENT ERROR Too much current has passed through the inverter Cycle the power to clear this error. If this error
bridge circuit of the unit. persists after a power cycle, contact Miller Electric
Mfg. Co. service department.

PRIMARY THERMISTOR The primary circuit thermistor is reading too high or Contact Miller Electric Mfg. Co. service department.
ERROR too low for a valid temperature.

SECONDARY THERMISTOR The secondary circuit thermistor is reading too high Contact Miller Electric Mfg. Co. service department.
ERROR or too low for a valid temperature.

PRIMARY VOLTAGE ERROR The primary voltage has exceeded the maximum Reduce the primary voltage to an acceptable level.
allowable limit.

PRIMARY CURRENT ERROR Too much current has passed through the primary Cycle the power to clear this error. If this error
circuit of the unit. persists after a power cycle, contact Miller Electric
Mfg. Co. service department.

PRIMARY BOOST NOT READY The primary boost has not successfully been Cycle the power to clear this error. If this error
established. persists after a power cycle, contact Miller Electric
Mfg. Co. service department.

7-5. Troubleshooting

Trouble Remedy
No weld output; unit completely Place line disconnect switch in On position.
inoperative.
Check and replace line fuse(s), if necessary, or reset supplementary protector.
Be sure power cord is plugged in and that receptacle is receiving input power.
No weld output; unit is on. Check and secure loose weld cable(s) into receptacle(s).
Check and correct poor connection of work clamp to workpiece.
Unit overheated causing thermal shutdown. Allow unit to cool with fan On (see Section 4-6,4-7 and
4-8).
Reduce duty cycle or amperage.
Check and correct blocked/poor airflow to unit (see Section 5-1).
Turn Power Off and back On again. If light continues to flash, check with Factory Authorized Service
Agent.
Line voltage too high or too low. Line voltage must be within ±10%.
Remote trigger left on. Turn off remote trigger, wait five seconds, and restart operation.
Erratic or improper welding arc or Use proper size and type of weld cable (see your Distributor).
output. Clean and tighten weld connections.
Verify electrode polarity; check and correct poor connections to workpiece.
Fan not operating. Unit not warmed up enough to require fan cooling.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor and control circuitry.
Stick welding problems: Hard starts; Use proper type and size of electrode.
poor welding characteristics; unusual
spattering. Verify electrode polarity; check and correct poor connections.
Make sure a remote control is not connected.
TIG welding problems: Wandering arc; Use proper type and size of tungsten.
hard starts; poor welding characteris-
tics; spattering problems. Use properly prepared tungsten.
Verify electrode polarity.
TIG welding problems: Tungsten Shield weld zone from drafts.
electrode oxidizing and not remaining Check for correct type shielding gas.
bright after welding.
Check and tighten gas fittings.
Verify electrode polarity.

OM-253 392 Page 42

Notes

OM-253 392 Page 43

 SECTION 8 − ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram

OM-253 392 Page 44
 264 018-A

OM-253 392 Page 45

 SECTION 9 − GMAW WELDING (MIG) GUIDELINES
9-1. Typical GMAW (MIG) Process Connections
! Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
Regulator/ close to the weld as possible.
Flowmeter

Wire Feeder/
Power Source

Gun
Shielding Gas

Gas
Workpiece

Work Clamp
GMAW1 2015−01 (GMAW Only) − Ref. 801 909-A

9-2. Typical GMAW (MIG) Process Control Settings

. These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure
they comply to specifications.

Material thickness determines weld

parameters. Convert Material
1/8 or 0.125 in.
Thickness to
Amperage (A)
(0.001 in. = 1 ampere)
0.125 in. = 125 A

Select Wire Size Select Wire Speed (Amperage)

Wire Size Amperage Range Wire Wire Speed

.035 in
Size Recommendation
(Approx.) 125 A based on 1/8 in.
0.023 in. 30 − 90 A
0.023 in. 3.5 in. per ampere 3.5 x 125 A = 437 ipm material thickness
0.030 in. 40 − 145 A ipm = inches per minute
0.035 in. 50 − 180 A 0.030 in. 2 in. per ampere 2 x 125 A = 250 ipm
0.035 in. 1.6 in. per ampere 1.6 x 125 A = 200 ipm

Voltage controls height and Wire speed (amperage) controls weld

width of weld bead. penetration (wire speed = burn-off rate)
Select Voltage

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)
Set voltage midway between high/low voltage

OM-253 392 Page 46

9-3. Holding And Positioning Welding Gun
. Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm)
past end of nozzle, and tip of wire is positioned correctly on seam.

1 1 Hold Gun and Control Gun

Trigger
2 Workpiece
3 3 Work Clamp
2 4 Electrode Extension (Stickout)
Solid Wire − 3/8 to 1/2 in.
(9 to 13 mm)
5 5 Cradle Gun and Rest Hand on
Workpiece
4

0°-15° 45° 0°-15°

90° 90°
45°

End View of Work Angle Side View of Gun Angle End View of Work Angle Side View of Gun Angle
GROOVE WELDS FILLET WELDS
S-0421-A

9-4. Conditions That Affect Weld Bead Shape

. Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed
(weld current), and voltage.

10° 10°

Push Perpendicular Drag

GUN ANGLES AND WELD BEAD PROFILES

Short Normal Long Short Normal Long

ELECTRODE EXTENSIONS (STICKOUT) FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

Slow Normal Fast

GUN TRAVEL SPEED S-0634

OM-253 392 Page 47

9-5. Gun Movement During Welding
. Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps,
a weave bead or multiple stringer beads works better.

1 Stringer Bead − Steady

Movement Along Seam
2 Weave Bead − Side To Side
Movement Along Seam
1 2 3 Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.

S-0054-A

9-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
1 5 Poor Penetration

2 3 4

S-0053-A
5

9-7. Good Weld Bead Characteristics

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During
Welding
Weld a new bead or layer for each
1 1/8 in. (3.2 mm) thickness in metals
being welded.
4 No Overlap
5 Good Penetration into Base
Metal

2 3 4

5 S-0052-B

OM-253 392 Page 48

9-8. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles that

cool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.

9-9. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets

in weld metal.

S-0635

Possible Causes Corrective Actions

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

9-10. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal

and hanging underneath weld.

Excessive Penetration Good Penetration

S-0639

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase travel speed.

OM-253 392 Page 49

9-11. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow

fusion between weld metal and
base metal.
Lack of Penetration Good Penetration
S-0638

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.

Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.

9-12. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with

base metal or a preceeding weld bead.

S-0637

Possible Causes Corrective Actions

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.

Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

9-13. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal

resulting in holes where no metal remains.

S-0640

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

OM-253 392 Page 50

9-14. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.

S-0641

Possible Causes Corrective Actions

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

Unsteady hand. Support hand on solid surface or use two hands.

9-15. Troubleshooting − Distortion

Distortion − contraction of weld metal during welding that forces

base metal to move.
Base metal moves
in the direction of
the weld bead.
S-0642

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

Notes

OM-253 392 Page 51

9-16. Common GMAW (MIG) Shielding Gases
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.

Application

Gas Short Circuiting Spray Arc Short Circuiting Spray Arc Short Circuiting
Spray Arc Steel
Steel Stainless Steel Stainless Steel Aluminum Aluminum

Argon All Positions5 All Positions

Flat & Horizontal5 Flat & Horizontal5

Argon + 1% O2
Fillet Fillet

Flat & Horizontal5 Flat & Horizontal5

Argon + 2% O2
Fillet Fillet

Flat & Horizontal5

Argon + 5% O2
Fillet

Flat & Horizontal5

Argon + 8% CO2 All Positions
Fillet

Argon + 25% Flat & Horizontal1

All Positions All Positions4
CO2 Fillet

Argon + 50%
All Positions
CO2

Flat & Horizontal1

CO2 All Positions
Fillet

Helium All Positions2

Argon + Helium All Positions2

Tri-Mix4 All Positions

1 Globular Transfer
2 Heavy Thicknesses
3 Single Pass Welding Only
4 90% HE + 7-1/2% AR + 2-1/2% CO2
5 Also for GMAW-P, All Positions

9-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause Remedy
Wire feed motor operates, but Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.
wire does not feed.
Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match
wire size and type if necessary.

Wire spool brake pressure too high. Decrease brake pressure on wire spool.

Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.

Wire curling up in front of the Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.
wire feed rolls (bird nesting).
Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner length
and diameter, replace if necessary.

Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.

Dirty or damaged (kinked) liner. Replace liner.

OM-253 392 Page 52

Problem Probable Cause Remedy
Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder.

Gas nozzle plugged. Clean or replace gas nozzle.

Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.

Restriction in gas line. Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.

Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.

Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gas
solenoid valve.

Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source. for correct voltage.

Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn
drive rolls if necessary.

Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.

Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
welding power source.

Loose connections at the gun weld cable or work cable. Check and tighten all connections.

Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.

OM-253 392 Page 53

 SECTION 10 − STICK WELDING (SMAW) GUIDELINES
10-1. Stick Welding Procedure
! Weld current starts when
electrode touches work-
piece.
! Weld current can damage
electronic parts in vehicles.
Disconnect both battery
Tools Needed: Equipment Needed: cables before welding on a
vehicle. Place work clamp
as close to the weld as
possible.
. Always wear appropriate per-
sonal protective clothing.
1 Workpiece
Make sure workpiece is clean be-
fore welding.
2 Work Clamp
Place as close to the weld as
Constant Current possible.
Welding Power Source 3 Electrode
Before striking an arc, insert an
electrode in the electrode holder. A
small diameter electrode requires
less current than a large one. Fol-
low recommendations of the elec-
trode manufacturer when setting
weld amperage (see Section
10-2).
5
4 Insulated Electrode Holder
4
5 Electrode Holder Position
2
6 Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound. Correct
arc length is related to electrode di-
ameter. Examine the weld bead to
determine if the arc length is cor-
3 rect.
Arc length for 1/16 and 3/32 in. dia-
6 meter electrodes should be about
1/16 in. (1.6 mm); arc length for 1/8
1 7 and 5/32 in. electrodes should be
about 1/8 in. (3 mm).
7 Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
making another weld pass.

stick 2015 - 04 − 151 593

OM-253 392 Page 54

10-2. Electrode and Amperage Selection Chart

AMPERAGE
RANGE

PENETRATION
ELECTRODE

ELECTRODE

POSITION
DIAMETER

USAGE
DC*

AC
100

150

200

250

300

350

400

450
50

3/32 6010 EP ALL DEEP MIN. PREP, ROUGH

1/8 6011 EP ALL DEEP HIGH SPATTER
6010
5/32
& 3/16 6013 EP,EN ALL LOW GENERAL
6011 7/32 SMOOTH, EASY,
1/4 7014 EP,EN ALL MED FAST
1/16 LOW HYDROGEN,
5/64 7018 EP ALL MED
STRONG
3/32 FLAT
1/8 7024 EP,EN HORIZ LOW SMOOTH, EASY,
6013 FILLET FASTER
5/32
3/16 NI-CL EP ALL LOW CAST IRON
7/32
308L EP ALL LOW STAINLESS
1/4
3/32 *EP = ELECTRODE POSITIVE (REVERSE POLARITY)
1/8 EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
7014 5/32
3/16
7/32
1/4
3/32
1/8
5/32
7018
3/16
7/32
1/4
3/32
1/8
5/32
7024
3/16
7/32
1/4
3/32
1/8
Ni-Cl
5/32
3/16
3/32
308L 1/8
5/32
Ref. S-087 985-A

10-3. Striking an Arc

! Weld current starts when elec-
trode touches workpiece.
1 Electrode
2 Workpiece
1 3 Arc
Scratch Technique
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out,
2 electrode was lifted too high. If elec-
trode sticks to workpiece, use a quick
twist to free it.
3 Tapping Technique
Bring electrode straight down to
1 workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.

3
S-0049 / S-0050

OM-253 392 Page 55

10-4. Positioning Electrode Holder
1 End View Of Work Angle
2 Side View Of Electrode
Angle
After learning to start and hold
an arc, practice running beads
1
of weld metal on flat plates using
a full electrode.
10°-30° Hold the electrode nearly per-
2
pendicular to the work, although
tilting it ahead (in the direction of
90° 90°
travel) will be helpful.

. To produce the best results,

hold a short arc, travel at a
uniform speed, and feed the
electrode downward at a
Groove Welds constant rate as it melts.

10°-30°
1 45° 2

45°

Fillet Welds

S-0060

10-5. Poor Weld Bead Characteristics

1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration
4

2 3

5
1
S-0053-A

10-6. Good Weld Bead Characteristics

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
2 3 4 5 4 No Overlap
5 Good Penetration into Base
Metal

S-0052-B

OM-253 392 Page 56

10-7. Conditions That Affect Weld Bead Shape

. Weld bead shape is affected

by electrode angle, arc
length, travel speed, and thick-
ness of base metal.
Correct Angle
Angle Too Small 10° - 30° Angle Too Large

Electrode Angle

Drag

Spatter

Arc Length
Too Short Normal Too Long

Travel Speed
Slow Normal Fast

S-0061

10-8. Electrode Movement During Welding

. Normally, a single stringer

bead is satisfactory for most
narrow groove weld joints;
however, for wide groove weld
1 2 joints or bridging across gaps,
a weave bead or multiple
stringer beads work better.
1 Stringer Bead − Steady
Movement Along Seam
2 Weave Bead − Side to Side
Movement Along Seam
3 3 Weave Patterns
Use weave patterns to cover a
wide area in one pass of the elec-
trode. Do not let weave width ex-
ceed 2-1/2 times diameter of
electrode.

S-0054-A

10-9. Welding Lap Joints

1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.
3 Multi-Layer Fillet Weld
30°
30° Or Less Weld a second layer when a heavi-
Or Less er fillet is needed. Remove slag be-
fore making another weld pass.
1 1 Weld both sides of joint for maxi-
mum strength.

2 3
S-0063 / S-0064

OM-253 392 Page 57

10-10. Welding Groove (Butt) Joints
1 Tack Welds
Prevent butt joint distortion by tack
welding the materials in position
before final weld.
Workpiece distortion occurs when
heat is applied locally to a joint.
1 One side of a metal plate will “curl”
up toward the weld. Distortion will
2 also cause the edges of a butt joint
to pull together ahead of the elec-
trode as the weld cools.
2 Square Groove Weld
3 Single V-Groove Weld
4 Double V-Groove Weld
Materials up to 3/16 in. (5 mm)
thick can often be welded without
special preparation using the
square groove weld. However,
when welding thicker materials it
may be necessary to prepare the
edges (V-groove) of butt joints to
30° ensure good welds.
1/16 in.
(1.6 mm) The single or double V-groove
weld is good for materials 3/16 −
3/4 in. (5-19 mm) thick. Generally,
the single V-groove is used on ma-
terials up to 3/4 in. (19 mm) thick
3 4 and when, regardless of thickness,
you can weld from one side only.
Create a 30 degree bevel with oxy-
acetylene or plasma cutting equip-
ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.

S-0062

10-11. Welding Tee Joints

1 Electrode
2 Fillet Weld
Keep arc short and move at defi-
nite rate of speed. Hold electrode
as shown to provide fusion into the
corner. Square edge of the weld
surface.
For maximum strength weld both
sides of upright section.
3 Multi-Layer Deposits
Weld a second layer when a heavi-
er fillet is needed. Use any of the
1 weaving patterns shown in Section
1
10-8. Remove slag before making
another weld pass.

45°
Or
2 2
Less 3

S-0060 / S-0058-A / S-0061

OM-253 392 Page 58

10-12. Weld Test
1 Vise
2 Weld Joint
3 Hammer
Strike the weld joint in the direction shown. A good weld
bends over but does not break.
3
If the weld breaks, examine it to determine the cause.
If the weld is porous (many holes), the arc length was
3 probably too long.
2 To 3 in. If the weld contains bits of slag, the arc may have been
(51-76 mm) too long or the electrode was moved incorrectly which
2 To 3 in. allowed molten slag to be trapped in the weld. This may
(51-76 mm) happen on a V-groove joint made in several layers and
2 2 calls for additional cleaning between layers.
1/4 in.
(6.4 mm) 1 1 If the original beveled surface is visible the material was
not fully melted which is often caused by insufficient
heat or too fast a travel speed. S-0057-B

10-13. Troubleshooting
Porosity − small cavities or holes resulting from gas pockets in weld metal.

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

Damp electrode. Use dry electrode.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.

Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding
weld bead.

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.

OM-253 392 Page 59

 Lack Of Penetration − shallow fusion between weld metal and base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique. Keep arc on leading edge of weld puddle.

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

Excessive Penetration − weld metal melting through base metal and hanging underneath weld.

Excessive Penetration Good Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

Burn-Through − weld metal melting completely through base metal resulting in holes where no
metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

Distortion − contraction of weld metal during welding that forces base metal to move.

Base metal moves

in the direction of
the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-253 392 Page 60

SECTION 11 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2013-10

Whenever possible and practical, use DC weld output instead of AC weld output.

11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten )
. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter (DCEN) − Argon AC − Argon
Direct Current Electrode Negative Balance Control @ 65% Electrode Negative
(For Use With Mild Or Stainless Steel) (For Use With Aluminum)

2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens

.010 in. (.25 mm) Up to 25 Up to 20
.020 in. (.50 mm) 15-40 15-35
.040 in. (1 mm) 25-85 20-80
1/16 in. (1.6 mm) 50-160 50-150
3/32 in. (2.4 mm) 130-250 135-235
1/8 in. (3.2 mm) 250-400 225-360
5/32 in. (4.0 mm) 400-500 300-450
3/16 in (4.8 mm) 500-750 400-500
1/4 in. (6.4 mm) 750-1000 600-800

♦Typical argon shielding gas flow rates are 11 to 35 CFH (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.

11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or

AC Welding With Inverter Machines
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires.
Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety
information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust
from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an
environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

2-1/2 Times 1 Grinding Wheel

Radial Grinding Electrode Diameter
Causes Wandering Arc Grind end of tungsten on fine grit, hard
2 3 abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
1 contaminated causing lower weld quality.
2 Tungsten Electrode
A 2% ceriated tungsten is recommended.
3 Flat
4
Wrong Tungsten Diameter of this flat determines amperage
Preparation Ideal Tungsten Preparation − Stable Arc capacity.
4 Straight Ground
Grind lengthwise, not radial.

OM-253 392 Page 61

 SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW)
12-1. Positioning The Torch
! Grinding the tungsten electrode
produces dust and flying sparks
which can cause injury and start
fires. Use local exhaust (forced
ventilation) at the grinder or wear
3 an approved respirator. Read
MSDS for safety information.
Consider using cerium or lantha-
2 num based tungsten instead of
thoriated. Thorium dust contains
low-level radioactive material.
Properly dispose of grinder dust
in an environmentally safe way.
4 Wear proper face, hand, and
body protection. Keep flam-
mables away.
90° 1 Workpiece
1 Make sure workpiece is clean before
welding.
2 Work Clamp
Place as close to the weld as possible.
3 Torch
4 Filler Rod (If Applicable)
10−15° 5 Gas Cup
4 6 Tungsten Electrode
Select and prepare tungsten according
5 to Section 11.
10−25° 6 Guidelines:
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate
shielding gas coverage. (For example,
5 if tungsten is 1/16 in. diameter, gas cup
6
should be a minimum of 3/16 in.
diameter.
Tungsten extension is the distance the
tungsten extends out gas cup of torch.
The tungsten extension should be no
1/16 in. greater than the inside diameter of the
gas cup.
3/16 in. Arc length is the distance from the
tungsten to the workpiece.
Bottom View Of Gas Cup

Ref. ST-161 892

OM-253 392 Page 62

12-2. Torch Movement During Welding
Tungsten Without Filler Rod

Welding direction 75°

Form pool Tilt torch Move torch to front

of pool. Repeat process.

Tungsten With Filler Rod

75° 15°
Welding direction

Form pool Tilt torch Add filler metal

Remove rod Move torch to front

of pool. Repeat process.
ST-162 002-B

12-3. Positioning Torch Tungsten For Various Weld Joints

Butt Weld And Stringer Bead “T” Joint

20°
90°

70°
75°

20°
15°
10°

Lap Joint Corner Joint

20-40°

90°

75° 75°

15°
15°
30°
ST-162 003 / S-0792

OM-253 392 Page 63

 SECTION 13 − PARTS LIST
13-1. Recommended Spare Parts

Part
No. Description Quantity
235 570 Q−150 MIG Gun

. . . . . . . . . 194 010 . . . . . . . . . . . . . . Liner, Monocoil .023−.025 15 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . 194 011 . . . . . . . . . . . . . . Liner, Monocoil .030−.035 15 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . 194 012 . . . . . . . . . . . . . . Liner, Monocoil .035−.045 15 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . QJL−2330 . . . . . . . . . . . . . Liner, Jump Steel .023−030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . QJL−3545 . . . . . . . . . . . . . Liner, Jump Steel .035−.045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 4323R . . . . . . . . . . . . . . . Insulator, Nozzle (small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . DS−1 . . . . . . . . . . . . . . . Diffuser, Centerfire (small nozzle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . T−023 . . . . . . . . . . . . . . . Tip, Centerfire .023 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . T−030 . . . . . . . . . . . . . . . Tip, Centerfire .030 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . T−035 . . . . . . . . . . . . . . . Tip, Centerfire .035 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . T−045 . . . . . . . . . . . . . . . Tip, Centerfire .045 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . NS−1200B . . . . . . . . . . . . . Nozzle, Centerfire Small Brass 1/2 in. Flush . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . NS−5818C . . . . . . . . . . . . . Nozzle, Centerfire Small Copper 5/8 in. Recess 1/8 in. . . . . . . . . . . . . . . 1
. . . . . . . . NS−5800B . . . . . . . . . . . . . Nozzle, Centerfire Small Brass 5/8 in. Flush . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . NS−5818B . . . . . . . . . . . . . Nozzle, Centerfire Small Brass 5/8 in. Recess 1/8 in. . . . . . . . . . . . . . . . . 1
. . . . . . . . NS−1218C . . . . . . . . . . . . . Nozzle, Centerfire Small Copper 1/2 in. Recess 1/8 in. . . . . . . . . . . . . . . 1
. . . . . . . . NS−1218B . . . . . . . . . . . . . Nozzle, Centerfire Small Brass 1/2 in. Recess 1/8 in. . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 4478 . . . . . . . . . . . . . . . O−Ring, MIG Gun Power Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

13-2. Drive Rolls

PART NO. WIRE DIAMETER INCHES (mm)
261 157 .024 (.6), .030/.035 (.8 and .9) (Standard) and .030/.035 (.8 and .9) (VK Groove)
♦202 179 .024 (.6) and .030/.035 (.8 and .9) (Standard)
♦202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove)
♦ Optional

. A complete Parts List is available on−line at www. MillerWelds. com

OM-253 392 Page 64

Notes
Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
 Effective January 1, 2015
(Equipment with a serial number preface of MF or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective * Bernard Guns (No Labor)
1-800-4-A-MILLER date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
for your local workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
Miller distributor. OR IMPLIED, INCLUDING THE WARRANTIES OF * Accessory (Kits)
MERCHANTABILITY AND FITNESS. * Canvas Covers
Within the warranty periods listed below, Miller will repair or replace * Induction Heating Coils and Blankets, Cables, and
any warranted parts or components that fail due to such defects in Non-Electronic Controls
Your distributor also gives material or workmanship. Miller must be notified in writing within * M-Guns
you ... thirty (30) days of such defect or failure, at which time Miller will * MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be * Remote Controls and RFCS-RJ45
Service followed. If notification is submitted as an online warranty claim, the
You always get the fast, * Replacement Parts (No labor)
claim must include a detailed description of the fault and the * Roughneck Guns
reliable response you troubleshooting steps taken to identify failed components and the
need. Most replacement cause of their failure.
* Spoolmate Spoolguns
parts can be in your Miller’s True Blue® Limited Warranty shall not apply to:
Miller shall honor warranty claims on warranted equipment listed
hands in 24 hours. 1. Consumable components; such as contact tips,
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment cutting nozzles, contactors, brushes, relays, work
Support station table tops and welding curtains, or parts that
to the original end-user purchaser, and not to exceed twelve months
Need fast answers to the fail due to normal wear. (Exception: brushes and
after the equipment is shipped to a North American distributor or
tough welding questions? eighteen months after the equipment is shipped to an International relays are covered on all engine-driven products.)
Contact your distributor. distributor. 2. Items furnished by Miller, but manufactured by others,
The expertise of the 1. 5 Years Parts — 3 Years Labor such as engines or trade accessories. These items are
distributor and Miller is covered by the manufacturer’s warranty, if any.
* Original Main Power Rectifiers Only to Include SCRs,
there to help you, every Diodes, and Discrete Rectifier Modules 3. Equipment that has been modified by any party other than
step of the way. Miller, or equipment that has been improperly installed,
2. 3 Years — Parts and Labor
improperly operated or misused based upon industry
* Auto-Darkening Helmet Lenses (Except Classic standards, or equipment which has not had reasonable
Series) (No Labor) and necessary maintenance, or equipment which has
* Engine Driven Welder/Generators been used for operation outside of the specifications for
(NOTE: Engines are Warranted Separately by the the equipment.
Engine Manufacturer.)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Inverter Power Sources (Unless Otherwise Stated) USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
* Plasma Arc Cutting Power Sources TRAINED AND EXPERIENCED IN THE USE AND
* Process Controllers MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Transformer/Rectifier Power Sources exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
3. 2 Years — Parts and Labor
cases, (3) the reasonable cost of repair or replacement at an
* Auto-Darkening Helmet Lenses − Classic Series Only authorized Miller service station; or (4) payment of or credit for the
(No Labor) purchase price (less reasonable depreciation based upon actual
* Fume Extractors − Capture 5, Filtair 400 and Industrial use) upon return of the goods at customer’s risk and expense.
Collector Series Miller’s option of repair or replacement will be F.O.B., Factory at
4. 1 Year — Parts and Labor Unless Specified Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
* Automatic Motion Devices as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
* CoolBelt and CoolBand Blower Unit (No Labor)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Desiccant Air Dryer System
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* External Monitoring Equipment and Sensors REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Field Options DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
(NOTE: Field options are covered for the remaining CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
warranty period of the product they are installed in, or WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
for a minimum of one year — whichever is greater.) LEGAL THEORY.
* RFCS Foot Controls (Except RFCS-RJ45) ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* Fume Extractors − Filtair 130, MWX and SWX Series IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
* HF Units CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
* ICE/XT Plasma Cutting Torches (No Labor) BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
* Induction Heating Power Sources, Coolers OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
(NOTE: Digital Recorders are Warranted Separately DEALING, INCLUDING ANY IMPLIED WARRANTY OF
by the Manufacturer.) MERCHANTABILITY OR FITNESS FOR PARTICULAR
* LiveArc Welding Performance Management System PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Load Banks FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
* Motor-Driven Guns (except Spoolmate Spoolguns)
Some states in the U.S.A. do not allow limitations of how long an
* PAPR Blower Unit (No Labor) implied warranty lasts, or the exclusion of incidental, indirect,
* Positioners and Controllers special or consequential damages, so the above limitation or
* Racks exclusion may not apply to you. This warranty provides specific
* Running Gear/Trailers legal rights, and other rights may be available, but may vary from
* Spot Welders state to state.
* Subarc Wire Drive Assemblies In Canada, legislation in some provinces provides for certain
* Water Coolant Systems additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
* TIG Torches (No Labor) exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province. miller_warr 2015-01
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2015 Miller Electric Mfg. Co. 2015−01